Method of and means for forming hinge seats



June 12, 1962 E. FORWARD METHOD OF AND MEANS FOR FORMING HINGE SEATS 5 Sheets-Sheet 1 Filed March 17, 1961 Wren/0r E. Forward fl/Ybrney June 12, 1962 E. FORWARD METHOD OF AND MEANS FOR FORMING HINGE SEATS Filed March 17, 1961 5 SheetsSheefc 2 June 12, 1962 E. FORWARD METHOD OF AND MEANS FOR FORMING HINGE SEATS 5 Sheets-Sheet 5 u kw U 0 0 o Filed March 17, 1961 f. l b/Ward r June 12, 1962 E. FORWARD METHOD OF AND MEANS FOR FORMING HINGE SEATS 5 Sheets-Sheet 4 Filed March 17 m T w i..- I I I l l l I 1 I I I I I I l I I I I I l I l I I 1 I l I I |I lll I I I I l i l I l I l I I IHHI H L fi l lw I l l l v I l l I l l I I l I I l l I I l l l I I4. I I I I ll IJIIIH I11 fmwmww "r M hm. nh h rmm rq T7 mm vw QN III! h m I ww 8 m W 6 m WF. m

June 12, 1962 E. FORWARD METHOD OF AND MEANS FOR FORMING HINGE SEATS 5 Sheets-Sheet 5 Filed March 17, 1961 //7venf0r f. l b/ward finite 3,638,509 Patented June 12, 1%62 3,038,509 METHOD F AND MEANS FOR FGRMING HINGE SEATS Eugene Forward, Maple Ave, Hudson Heights, Quebec, Canada Filed Mar. 17, 1961, Ser. No. 96,566 12 Claims. (Cl. Mi l-27) This invention relates to improvements in the method of and means for cutting hinge seats in doors and windows and in the frames thereof and the main object of the invention is to provide for the simultaneous cutting of hinge seats in a door or window and its frame whereby the seats of the door or Window will be in exact register with those in the frame and both will be exactly the required size. A further object is to provide for the easy and expeditious cutting of hinge seats as aforesaid in a range of sizes. A still further object is to provide for the cutting of hinge seats as aforesaid in suchwise that the seats of the door or window and its frame are parallel to one another or are in divergent relation to one another. Another object is to provide a power driven tool which may be easily operated by one person to cut hinge seats in a fraction of the time that would be required to cut them by hand. Various other objects and the advantages of the invention may be ascertained from the following description and the accompanying drawings.

For brevity, reference will be made hereinafter only to doors but it will be understood that the invention relates equally to windows.

At the present time hinge seats in doors and the frames thereof are cut separately and by hand and the operation is time consuming and therefore expensive. Moreover, unless great skill and care are exercised the seats are liable to be of inexact depth or out of register, or both, so that after hinges are applied, considerable adjustment or shimrning may be necessary to obtain a proper hang to a door. According to this invention the foregoing disadvantages of present methods may be completely avoided, chiefly by mechanical cutting of the seats in both a door and its frame in a single operation.

Broadly speaking, the invention consists as to metrod, and after a door has been fitted to its frame, in applying tool hangers to embrace the hinge edge of the door at predetermined distances above the desired locations of the hinge seats to be formed and then setting the door in its frame and against its stops, the hangers being of such thickness as to space the hinge edge of the door from its frame a proper distance for hinge seat cutting. The tool of this invention, which includes a chain-type saw, is then hung on the hangers, successively, with the central plane of the saw centered with respect to the clearance between the door and its frame and is pressed against the door, and in each such position is operated to force the saw into the door and its frame so that hinge seats are cut in exact register with one another and both to exactly the same and proper dimensions.

As to apparatus, the invention consists broadly speaking in provision of a frame including a base plate to rest against a door and its frame, a saw carrier head slidable in the frame toward and away from the door, a chain-type saw mounted on said carrier and motor means operatively connected to the saw.

In greater detail, the invention consists in the features and combinations of features herein described and illustrated together with all such modifications thereof and substitutions of equivalents therefor as are within the scope of the appended claims.

In the accompanying drawings which illustrate a preferred embodiment of the invention together with modi fications thereof but to which embodiments and modifications and the details thereof the invention is not limited:

FIG. 1 is a front elevation showing one embodiment of the invention in operative relation to a door and its frame.

FIG. 2 is an elevation of the right hand side of the apparatus as illustrated in FIG. 1.

FIG. 3 is an elevation of the left hand paratus as illustrated in FIG. 1.

FIG. 4 is an inverted plan view looking up at the apparatus as illustrated in FIG. 1.

FIG. 5 (Sheet 2) is a plan view of the saw carrier unit shown in FIG. 1 in elevation.

PEG. 6 (Sheet 1) is a plan View of the hanger shown in FIGS. 1 and 2.

FIG. 7 (Sheet 5) is an inverted plan view of another embodiment of the invention, showing the apparatus in the same relation to a door and its frame as is the apparatus of FIG. 4.

FIG. 8 is a vertical cross-section on the line 8-3 of FIG. 7.

FIG. 9 (Sheet 3) is a diagrammatical illustration of a set of saw carrier units.

FIG. 10 is a diagrarnmatical illustration of a set of hangers.

Referring more particularly to the drawings, 11 designates a door, 12 the frame thereof and 13 the clearance between the hinge edge of the door and the frame. Using the term saw to designate generally the powered chain-type saw of this invention and using the terms upper and lower with reference to the normal operat ing position of the saw relatively to a door as shown in the drawings, 14 designates a base plate adapted to rest flat against a door and its frame and to span the clearance 13. The base plate is formed with openings 15 near its upper and lower edges for engagement severally with a hook-type hanger 16 releasably attached to the hinge edge of the door in such position that the saw may be supported in proper operating position on the door, all as shown in FIG. 1 wherein the saw is shown related to the right hand edge of the door. If hinge seats are to be cut in the left hand edge of the door, the hangers 16 are applied to that edge and the saw sup ported thereon in inverted position relatively to the showing of FIG. 1. The base plate is formed with an elongated opening 17 which is centered with respect to the clearance 13 and is provided with lugs 18 springing from its door engaging surface to engage the edge of the door and hold the plate in position so that the opening 17 is centered and parallel with respect to the clearance 13.

Spaced upper and lower guides 19 extend from the base plate away from the door. The adjacent surfaces of the guides are formed with grooves 20 to slidably receive a head plate 21, whereby the plate may be moved toward and away from the door. The guides may be rigidly related to the base plate, as shown in FIG. 7, or may be pivotally connected at their lower ends to the base plate by trunnions 22 journalled in lugs 23 extending from the base plate, so as to have capacity side of the apfor tilting movement to right and left of a central position in which they are normal to the base plate, as indicated in FIG. 4. The amplitude of tilting movement is limited by stops 24 mounted on a column 25 paralleling one of the guides. The column carries also a pivoted locking bolt 26 to engage in the adjacent guide 19 to hold the latter normal to the base plate when no tilting capacity is desired so that, when so locked, the guide is, for all practical purposes, rigidly connected to the base plate. A cover plate 27 connected to both guides ensures that both of them have the same limitation of tilting movement or are both held rigidly relatively to the base plate. Obviously, the elements 25 and 26 may be, if desired, associated with the other guide but now are not deemed to be necessary. It will be understood that the saw may be constructed with the guides either tiltable or permanently rigidly attached to the base plate.

Mounted on the head plate 21 is a chain saw carrier and drive unit, best shown in FIGS. 2 and 5, which comprises a carrier plate 28 bolted to the head plate 21 and carrying, at one end, a chain saw drive sprocket 29 and at the other end a chain saw guide 30. The guide 30 is attached to the carrier plate 28 by bolts 31 passing through slots 32 in the guide and into the carrier plate, whereby the distance between the guide and sprocket may be adjusted to properly tension the saw chain 33 trained over the guide and the sprocket. Any suitable adjusting means may be provided, such as a screw 34 threaded through a lug of the plate 28 and bearing against the saw guide. The profile of the free end of the saw guide determines the path the saw chain will follow and therefore the size and shape of the cut it will make. In FIG. 2 the line 35 indicates the cut that will be made by a saw running over the guide shown in full lines in the same figure, while a saw running over a guide as indicated by the broken line 30 will make a cut as indicated by the line 35 The saw chain now preferred comprises two rows of outer links 36 and a single row of inner links 37 intermediate the rows of outer links and pivotally connected thereto in the well known manner. The outer links carry cutting teeth 38 on the outer side of the chain while the inner links are provided on the inner side of the chain with driving teeth 39.

The drive sprocket is of the shrouded type and is formed with recesses 40 to receive the driving teeth 39 of the chain and with shroudings 41 on which the outer links of the chain bear. The side and free end edges of the saw guide are formed with a groove 42 in which the drive teeth of the chain may run and with flanges 43 on which the outer links of the saw chain run. The driving teeth of the saw chain extend from flange to flange of the guide and from shrouding to shrouding of the sprocket thereby to hold the outer links against escape from the flanges 43 and shroudings 41.

In order that the tool may make cuts of different sizes to accommodate hinges of different sizes, it includes a series of saw chains of difierent lengths and widths and a series of guides and sprockets to match the chains. The principal differences are in the lengths of the chains, and in the sizes of the guides, as shown in FIG. 9. For making smaller and shallower hinge seats the rows of outer links are closer together, that is, the chain is narrower. The guides and sprockets therefor are also thinner. For this reason it is expedient to assembly each size of saw with its guide and drive sprocket into a unit, as shown in FIG. 5 so that such units may be easily interchanged on the head plate. For this purpose each of the sprockets is provided with a hub 45 revolubly mounted in the carrier plate and retained therein by any suitable means. The sprockets are each centrally apertured for splined connection with a driving shaft 46 and are clamped against a shoulder 47 of the shaft by a nut 48. As it is necessary that the central planes of the different saws be exactly the same distance from the adjacent face of the head plate 21, each carrier will include a distance piece of appropriate thickness which may be a boss on the carrier plate or may be a shim 49.

The saw driving shaft 46 may be the armature shaft of an electric motor 5% mounted on the head plate 21, on the opposite side thereof from the saw.

As shown in FIG. 3, spring means 51 is mounted in tension between the guides 19 and the head plate 21 and has capacity to more than counterbalance the weight of the head plate and all elements attached to it so as to normally hold these in the relation to the base plate illustrated, irrespective of the position of the tool.

In another embodiment of the invention as shown in FIG. 7, the shaft 46 is connected by bevel gears 52 and 53 to a shaft 54 mounted at one end in a bearing 55 on the base plate and in a second bearing 56 carried by a yoke 57 attached to the head plate on the opposite side thereof from the saw. The bearing 56 and a U-shaped extension 58 therefrom form a yoke which embraces the gear 53 to hold it in mesh with the gear 52. The bearing 56 also provides a bearing for the end of the shaft 46. The gear 53 is splined to the shaft 54 and is slidable therealong for a distance at least equal to the travel of the head plate in its guides. A spring 59 in compression surrounds the shaft 54 between the hearing 55 and the yoke extension 58 and has capacity to more than counterbalance the weight of the head plate and all elements carried by it so as to normally hold the parts in the relation to the base plate illustratedv As will best be seen in FIGS. 1, 4 and 7, the saw is centered opposite the base plate opening 17, which is large enough to give passage to the largest saw with which the tool is equipped and so that the saw may be advanced through the base opening to engage a door and frame to which the tool is applied. Bodily movement of the saw to engage and cut into the door and frame may be effected in diflerent ways. Preferably, the saw feeding movement is effected in both embodiments by means of a pull-type device, best shown in FIGS. 1, 3 and 4, and comprising a pair of rack toothed bars 60 slidable in grooves M in the guides 19, parallel with the grooves 20, and meshing with pinions 62 revolubly mounted on lugs 63 extending from the guides 19, which pinions mesh with rack toothed members 64 fixed to the opposite side of the head from the saw. The rack toothed bars 60 extend beyond the free ends of the guides and are connected by a handle 65. The operator holds the tool against the door by pressing with one hand against the base plate and feeds the saw by pulling the handle 65 toward himself, with his other hand.

Alternatively, saw feeding movement may be effected by pressing the motor in the embodiment of FIGS. 1 to 6 or the handle 65a in the embodiment of FIG. 7 or a cover (not shown) for the gears 52, 53 toward the door.

A stop 66 (FIG. 3) threaded into the base plate limits movement of the head plate toward the door While an extension 67 from the cover plate overlies the outer end of the head plate and holds it against escape from the guides under influence of the spring means 51 or 59. Generally speaking, the amplitude of movement of the head plate and saw is the same for all sizes of binge seats, the extent of penetration of the saw into the door and frame being determined by the different lengths of saw assemblies, as shown in FIG. 9, and the relative positions of the different saws on the head plate, as shown in FIG. 2. In other words, to cut any size of hinge seat within the capacity of the tool the head plate is moved toward the door until it engages the stop 66, the depth of the cut depending on the length of the saw assembly as measured from the axis of the shaft 46 and on the setting of the stop 66. By adjusting the stop 66 the extent of penetration of the saw into the door and frame may be regulated to determine the distance the hinge will extend beyond the door and frame.

The hangers 16 (FIGS. 6 and 10) are channel-shaped members each including a web 68 to lie against the edge of the door and side flanges 69 to snugly engage the inner and outer surfaces of the door. The web may have offset portions 70 to afford effective thickness greater than the actual thickness of the metal. One of the side flanges 69 is provided on its outer surface with a pair of mutually facing hooks 71. The Web carries, between the flanges, a preferably pointed spur 72. If the hangar is formed of sheet metal, the hooks and spur may be tongues struck up from the web and flanges. The provision of two mutually facing hooks 71 enables the hanger to be used on either vertical edge of a door. It will be understood that there will be at least two sets of hangers for each machine, each set including members in which the flanges are spaced at different distances apart, as shown in FIG. 10, and in accordance with a range of standard door thicknesses.

In practising the invention, after a door has been fitted to its frame to allow suitable clearance at the vertical edges, usually one-sixteenth of an inch, and before it is inserted in the frame, hangers 16 are applied to the hinge edge at such distances above the desired location of the upper and lower hinges that when the saw is hung on either of them the base plate opening 17 will register with the desired hinge location. The door is then placed in its frame and the webs of the hangers will space the hinge edge of the door from the adjacent frame suitably for hinge seat cutting, usually one-eighth of an inch. The effect will be to crowd the other vertical edge of the door against the adjacent frame. The saw is now hung on one of the hangers by engaging the lower hook 71 in the upper of the two base plate openings 15. The base lugs 18 lie against the edge of the door to hold the saw in proper alignment with the clearance between the door and its frame, ensuring that the central plane of the saw is centered relatively to the clearance 13. The door is then raised, as by wedges 73, to establish proper clearance from the lintle of the frame. Then, by holding the base against the door and pulling on the handle 64 .the saw chain is brought into cutting engagement with the door and frame, the teeth of one outer row of links engaging the door and the teeth of the other outer row of links engaging the frame. The cuttings fall away through the clearance 13. If the guides 19 are normal to the base plate 14 both hinge seats are cut in one operation. If, however, the guides are tilted successively to the extremes permitted by the stops 24 and the saw advanced after each tilting, the hinge seats formed will diverge inwardly from the faces of the door and frame, as is usually found necessary. In all cases the saw is fed into the work until movement is arrested by the head plate 21 contacting the stop 66. When a pair of hinge seats has been cut, the saw is moved to the other hanger and the above described operation repeated.

While only three members are shown in FIGS. 9 and 10 in each of the series of saw assemblies and of hangers it will be understood that each series may include as many more members as are desired or as are necessary to enable the tool to cut seats for hinges of a full range of standard sizes and in doors of a full range of standard thicknesses.

What I claim is:

1. Apparatus for forming hinge seats in doors or windows and frames therefor which apparatus comprises, a base to rest against a door or window; a pair of paralllel, spaced, grooved guides carried by said base, normal thereto in at least one plane; a head plate slidably mounted in said guides and movable toward and away from the base; a chain-type saw operatively mounted on one side of said head plate and extending beyond the head plate toward the base; a drive shaft for said saw, passing through the head plate; a driving motor at the other side of said head plate, operatively connected to said drive shaft; spring means to urge said head plate away from the base; rack toothed members slidable in said guides, parallel with the head rack; rack toothed members fixed to said head plate, parallel with and facing said first rack toothed members and pinions revoluble mounted on said guides and meshing with said first and second rack members.

2. In combination with apparatus according to claim 1 stop means to limit movement of the head plate under influence of said spring means.

3. In combination with apparatus according to claim 1 adjustable stop means to limit movement of the head plate toward the base.

4. In combination with apparatus according to claim 1 a saw carrier comprising a body removably attached to the head plate; a saw driving pinion revolubly mounted in said body and irrevolubly mounted on said shaft; and a grooved saw guide adjustably mounted on said body and movable toward and away from said pinion.

5. Apparatus according to claim 1 in which the guides are rigidly connected to the base.

6. Apparatus according to claim 1 including lugs projecting from the work engaging surface of the base for engagement with the edge of a door or window to align the saw with the adjacent edge surfaces of a door or window and its frame.

7. Apparatus according to claim 1 in which the base is formed with an opening form passage of the saw into engagement with a door or window and its frame.

8. Apparatus according to claim 1 in which the base is formed with openings near its upper and lower edges for engagement selectively with a hanger to support the apparatus on a door or window.

9. In combination with apparatus according to claim 1 a transmission shaft journalled at one end in the base plate; a second bearing for said transmission shaft, slidable therealong and mounted on the head plate; and bevel gears connecting said saw drive shaft and said transmission shaft, one of said gears being slidable but irrevoluble on said transmission shaft.

10. In combination with apparatus according to claim 1 a series of interchangeable, channel shaped hangers of different sizes for embracing engagement with the hinge edge portions of doors or windows of different thicknesses, each said channel member including a web to lie against the edge surface of a door or window and having a spur to engage in the edge surface of a door or window; flanges at the ends of said web to engage the inner and outer surfaces of a door or window; and a pair of mutually facing hooks on one said flanges, with either of which the base may be engaged to support the apparatus on a door or window.

11. Apparatus for forming hinge seats in doors or windows and frames therefor which apparatus comprises, a base to rest against a door or window; a pair of parallel, spaced, grooved guides carried by said base, normal thereto in at least one plane; a head plate slidably mounted in said guides and movable toward and away from the base; a chain-type saw operatively mounted on one side of said head plate and extending beyond the head plate toward the base; a drive shaft for said saw, passing through the head plate; a driving motor at the other side of said head plate, operatively connected to said drive shaft; spring means to urge said head plate away from the base; and at least one channel shaped hanger for embracing engagement with the hinge edge area of a door or window, said hanger including a web to lie against the edge surface of the door or window, flanges to engage the inner and outer surfaces of said door or window and means for retaining said hanger in such embracing engagement with the door or window, the hanger further including a hook engaging a slot in the base thereby supporting the base and the parts carried thereby in cutting position adjacent the hinge area of the door or window and frame therefor.

12. Apparatus according to claim 11, wherein a flange aoaaeos of said hanger has a pair of oppositely facing hooks either of which may engage a corresponding slot in the base to render the apparatus reversible.

References Cited in the file of this patent 5 UNITED STATES PATENTS 427,818 Young May 13, 1890 625,008 Wood May 16, 1899 1,012,241 Broadley Dec. 19, 1911 10 1,016,341 Lowden Feb. 6, 1912 8 Carlson May 12, 1914 Ahlvin June 30, 1914 Boese et a1. Mar. 1, 1927 Mohns Dec. 27, 1932 Zern Aug. 23, 1960 Sundby Nov..15, 1960 Kozak May 23, 1961 FOREIGN PATENTS Germany Feb. 14, 1927 Switzerland June 16, 1952 

